Thermoelectric Module Alignment Using Spherical Injection Portions
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Solution Overview
Problem
Existing methods for manufacturing thermoelectric modules are inefficient due to time-consuming alignment processes and high effort required for precise positioning of thermoelectric elements, especially with spherical shapes, which lead to increased defect rates and reduced efficiency due to difficulty in maintaining temperature differences between the hot and cold sides.
Innovation Solution
An apparatus with an alignment mechanism using a dispenser with injection portions and an oscillator for precise alignment of thermoelectric elements with non-flat end portions, paired with a bonding mechanism involving a heating cartridge and heat conducting portions to securely attach the elements to substrates, optimizing the contact area and adhesion for improved positioning and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If spherical thermoelectric elements are used for alignment, then alignment precision is improved, but stability of positioning deteriorates due to easy separation from fixed position
Solution Approach 1:
The patent uses spherical injection portions with curved inner surfaces to receive the thermoelectric elements. The spherical shape of the injection portions matches the spherical shape of the thermoelectric elements, providing precise alignment through geometric conformity while maintaining stable positioning through the curved contact surfaces.
Solution Approach 2:
The patent introduces an intermediary substance (adhesive or bonding material) into the injection portions to bond the thermoelectric elements to the electrodes. This intermediary ensures stable positioning by preventing separation while maintaining the alignment precision achieved through the spherical geometry.
2Measurement precision
If spherical thermoelectric elements are used, then alignment precision is improved, but temperature difference maintenance deteriorates due to difficulty in controlling distance between hot and cold sides
Solution Approach 1:
The patent changes the geometric parameters of the injection portions (inner diameter, depth, curvature radius) to optimize the positioning of spherical thermoelectric elements. By carefully controlling these parameters, the distance between the hot and cold sides of the elements is maintained at optimal values, ensuring sufficient temperature difference for efficient thermoelectric operation.
3Ease of operation
If robot arm is used for alignment, then positioning flexibility is improved, but manufacturing time increases due to sequential alignment of individual elements
Solution Approach 1:
The patent segments the alignment function into multiple fixed injection portions arranged in specific patterns on the substrate. Each injection portion is pre-configured to receive and position a thermoelectric element, eliminating the need for sequential robotic positioning and enabling parallel alignment of multiple elements.
Solution Approach 2:
The spherical thermoelectric elements self-align within the spherical injection portions through geometric constraints. The elements automatically assume their correct positions when placed in the injection portions, eliminating the need for active positioning control and reducing manufacturing time.
4Measurement precision
If alignment mechanism with separate positioning process is used, then positioning precision is improved, but operational complexity increases due to additional processes required
Solution Approach 1:
The patent merges the alignment and positioning functions into a single integrated structure of injection portions formed directly on the substrate. The injection portions simultaneously provide alignment guidance and final positioning, eliminating the need for separate positioning processes and reducing operational complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus significantly enhances manufacturing efficiency by allowing precise and rapid alignment and bonding of thermoelectric elements, reducing defect rates and ensuring a stable temperature difference, thereby improving the performance and efficiency of the thermoelectric module.
Implementation Method 1
The alignment mechanism may further include an oscillator connected to the dispenser to shake the dispenser.
Implementation Method 2
The bonding mechanism may have a heating cartridge generating heat and a plurality of heat conducting portion extending from the heating cartridge, and the plurality of heat conducting portions may be individually inserted into the plurality of injection portions.
Implementation Method 3
A thermoelectric module uses various methods of showing an interaction of heat with electricity and has a structure of using a Seebeck effect of generating an electromotive force by a temperature difference
Implementation Method 4
a structure of using a Peltier effect of absorbing (or generating) heat by a current
Data Source
AI summary
An apparatus for manufacturing a thermoelectric module includes an alignment mechanism for aligning a plurality of thermoelectric elements with respect to a plurality of electrodes attached to a substrate, wherein the alignment mechanism includes a dispenser having a plurality of injection portions and the plurality of thermoelectric elements is inserted into the plurality of injection portions.